I used a sheet of 1/8" black plastic. It was easy to cut to fit. the key with the plastic is to put it out in the sun so it will heat up and expand so when you have it all mounted and it cools down it won't be wavy. I did my roof on a really cold rainy day in the garage. Now that it is at a normal temp it is a bit wavy. It gets really bad in the desert heat.
Also check with your local sign shop, in our sign shop we have used aluma-panel its 1/8 double sided .032 gauge with a fiberglass core, light weight & strong comes in colors also, not much more money than .040 gauge alumn.
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